GB2161375A - Composite foam-seat cushion and method of preparation - Google Patents
Composite foam-seat cushion and method of preparation Download PDFInfo
- Publication number
- GB2161375A GB2161375A GB08509394A GB8509394A GB2161375A GB 2161375 A GB2161375 A GB 2161375A GB 08509394 A GB08509394 A GB 08509394A GB 8509394 A GB8509394 A GB 8509394A GB 2161375 A GB2161375 A GB 2161375A
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- United Kingdom
- Prior art keywords
- foam
- formulation
- soft
- layer
- cushion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
- B29C44/083—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another
- B29C44/086—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another and feeding more material into the enlarged cavity
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
- A47C27/146—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities on the outside surface of the mattress or cushion
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/02—Seat parts
- A47C7/18—Seat parts having foamed material included in cushioning part
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/751—Mattresses, cushions
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S297/00—Chairs and seats
- Y10S297/01—Foam
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Chair Legs, Seat Parts, And Backrests (AREA)
- Molding Of Porous Articles (AREA)
- Polyurethanes Or Polyureas (AREA)
Abstract
A composite foam seat cushion is comprised of foams of different firmnesses which are bonded to adjacent foams without adhesives or glues. The cushion has a supportive bottom (11) of one or more firm foams, a layer of soft foam (12) on the top of and supported by the bottom layer (11) a protective front foam cap (13) for the front edge of the layer of soft foam (12), a protective back foam cap (14) for the back edge of the layer of soft foam (12) and-side walls (15 and 16) of foam(s) of suitable firmness to provide support. A method of preparing the composite foam seat cushion is disclosed. <IMAGE>
Description
SPECIFICATION
Composite foam seat cushion and method of preparation
The present invention relates to a novel seat cushion and to a method of preparingvthe cushion.
Background of the invention
In the past, various methods have been used to make foam seat cushions which provide both support as well as a soft, comfortable seat. The methods of preparing such cushions for the most part have involved the bonding together with adhesives of different types of foams and or foams of different hardnesses to form a laminated cushion having the desired properties. Such methods are effective, but they are time consuming and relatively expensive.
In the Ahrens U.S. Pat. No. 4,190,697, a method is disclosed for producing a multidensity foam article suitable for use as a seat cushion without using adhesives. In the patented method, a foam cushion having a firm, high density foam bottom layer and a soft, low density foam top layer is prepared by placing a first formulation capable of yielding a firm foam into a mold, permitting said formulation to start rising and foaming, pouring a second liquid formulation capable of forming a soft foam through the rising first formulation so that the first formulation floats upon the second formulation, and then permitting the two formulations to foam, rise and cure into a multidensity foam article in which the foam layers of different density are bonded and knitted together at their common boundaries.
In the McEvoy U.S. Pat. No. 4,405,681, a method is disclosed for producing a foam cushion comprised of three different firmnesses without using adhesives. The resulting cushion has a firm foam base, a soft foam top or seat and a border of foam of an intermediate firmness.
It is generally recognized that the ideal foam seat cushion would be a composite formed of multiple foams of different firmness and properties to best suit the anatomy of the expected user. The Ahrens and
McEvoy methods and products are improvements over the prior art but a need still exists for a simple, fast, inexpensive method of preparing composite cushions having multiple areas of different firmness without piecing and glueing together pieces of foam.
Summary of the Invention
It is an object of the present invention to disclose a simple, fast, inexpensive method of preparing a composite foam seat cushion having foams of different firmnesses bonded together without adhesives.
It is a further object to disclose a novel composite foam seat cushion comprised of foams of different firmnesses in which the foams are bound together without using adhesives.
The composite foam cushion of the present invention has a bottom formed of one or more firm, supportive foams, a layer formed of one or more soft cushioning foams on top of the bottom layer, a front cap of firmer foam(s) encompassing and protecting the front edge of the soft foam layer, a back cap of still firmer more supportive form(s) encompassing and protecting the back edge of the soft foam layer and supportive side walls which are formed of one or more foams of different firmness than the soft foam layer. Each of the individual foams which form the composite foam cushion is bonded or knitted to the adjacent foams without the use of adhesives.
The method of the present invention of preparing the composite foam seat cushion comprises placing in the center of a suitable mold one or more relatively slow reacting formulations which produce firm supportive foams, placing in the front of the mold a formulation which will produce a foam of suitable properties for the front cap, placing in the back of the mold a formulation which will produce a foam of suitable properties for the back cap, and placing on the sides in the mold a formulation that will produce a foam of suitable properties for the sides of the cushion. The formulations in the mold are allowed to foam and start to rise until the formulations which will produce the front and back caps have started to gel and solidify but the foam still lacks structural integrity except where it is in contact with the heated mold and has solidified.Then one or more faster reacting formulations which produce a soft foam suitable for the cushioning layer are poured through the formulations in the mold. When the final formulations are added they are liquid and of higher specific gravity than the already foaming formulations, therefore the portions of the foaming formulations which have not yet completely gelled or set will be displaced and will float upon the final soft formulations. The mold is then closed and the formulations are allowed to cream, foam and rise to fill the mold. When sufficiently formed, the composite foam seat cushion is removed from the mold and further cured. It is inverted ISO for use as a cushion.
The length of time that the first formulations are allowed to cream, rise and, if desired, gel will depend on the reaction rates of the foams being utilized, primarily the reaction rate of the first foam formulations. If the mass of the first formulations has increased too far in the foaming reaction, the viscosity of the mass will ba such that the final formulation(s) being added will not be able to penetrate. On the other
hand, if the foaming reaction of the first and intermediate formulations has not advanced sufficiently, the formulations will commingle and the resulting article will not exhibit the desired stratified layers of foams of different firmness.
The above mentioned and other objects will be apparent to those skilled in the art from the description
of the preferred embodiment and the drawings.
Brief description of the drawings
Figure 1 is the perspective view of the preferred embodiment of the composite foam seat cushion of the present invention.;
Figure 2 is a top view of the cushion of Figure 1 with various sections labeled with letters;
Figure 3 is a side elevational view of one embodiment of the invention taken along lines 3-3 in Figure 2;
Figure 4 is a view in section taken along the line 4-4 in Figure 2;
Figure 5 is a view similar to Figure 3 of another embodiment of the invention;
Figure 6 is a view similar to Figure 4 of the embodiment of Figure 5;
Figure 7 is a perspective view of an open mold in which the composite foam seat cushion may be produced;
Figure 8 is a plan view of the mold of Figure 7 with the first formulation therein;
Figure 9 is a view similar to Figure 8 with additional formulations therein;;
Figure 10 is a side elevational view in section and taken along line 10-10 in Figure 9 showing the formulations after they have creamed and commenced to rise;
Figure ills a view similar to Figure 10 showing the mold after the soft foam formulation has been added; and
Figure 12 is a view similar to Figure 10, but with the lid of the mold closed and the foams completely filling the mold.
Description of the preferred embodiment
In Figures 1 to 4 of the drawings is seen one embodiment of a composite foam cushion 10 of the present invention which is suitable for use as a vehicle seat cushion.
The cushion 10 as seen best in Figures 3 and 4 is comprised of a firm foam bottom layer 11, a soft foam top layer 12 which is partially encapsulated on the sides by layer 11, a front foam cap 13, a back foam cap 14 and side 15 and 16 which also are of foam. All the foams are bonded or knitted together during the molding process, thus making the use of adhesives or glues unnecessary.
The function of the layer 11 is to provide the cushion with a firm supportive bottom. The layer 12 provides a soft, comfortable load distributor which gives the overall cushion a soft and luxurious feel.
The front cap 13 is of a firm and tough foam; it protects the front of the less durable soft layer and provides support for the front of the cushion. The back cap is firm and provides additional support and strength at the back of the cushion, in addition, to protecting the back of the soft layer. The sides 15 and 16 can be of the same or different firmness depending upon the level of support desired in those areas of the cushion. For example, if the cushion is used as a vehicle seat the side closest to the door should be of a tougher and more durable foam than the other side to withstand wear caused by entry and exit from the vehicle.
The method of preparing the embodiment of the composite foam seat cushion 10 of Figures 3 and 4 will now be described in connection with Figures 2 and 7 to 12 of the drawings.
The composite foam cushion 10 is prepared in a mold 17 such as that best seen in Figures 7 and 8.
The mold 17 which is of metal, such as diecast aluminium, includes a lid 18 and a container 19. Toggle clamps 20, 21 and 22 are provided for securing the lid 18 to the container 19. The interior of container 19 is coated with a suitable release agent e.g. silicone. The mold 17 is preferably placed on a conveyor line (not shown) and liquid formulations for the foams poured into the mold which is heated to about 100 to about 120cm.
In a preferred practice of the method of the present invention, a first liquid formulation 23 which will form the bottom layer 11 is poured into the mold 17 covering Sections DGD (refer to Figure 2) of the mold. Immediately, before the first formulation 23 creams or rises, a second formulation 24 which will form the front cap 13 is poured into Section EHE and a third formulation 25 which will form the back cap 14 is poured into Sections CFC of the mold (Figure 8). Before any of the already poured formulations can rise or cream substantially, formulations 26a and 26b, which can be the same or different, are poured into the side or wing portions A and B of the mold, respectively. The entire bottom of the mold is now covered with foam formulations (Figure 9).After a suitable time delay of about 35 to about 55 seconds the poured formulations cream and rise to about 10% to about 60% of their potential rise (Figure 10) and the portions of the formulations which produce the front and back caps 13 and 14 and which are in contact with the heated mold have gelled and the resulting foam has solidified and has structural integrity. A liquid formulation 27 which will form the soft foam layer 12 is then poured into the mold 17 through the centers of the first formulation 23 in Sections DGD and the formulations 24 and 25 in Sections EHE and
CFC, respectively. The creaming and rising formulation 23 which is now of lower density is displaced by and floats on formulation 27 (Figure 11). In addition the portions of the formulations 24 and 25 that are still creaming, rising and lack structural integrity also float. However, the portions of formulations 24 and 25 which are in contact with the heated mold and which have gelled and solidified do not float; thus the front and back caps are formed. If it is desired to encapsulate the soft foam layer 12, the firm foam formed by formulation 23, the formulation 27 is not poured until the portion of formulation 23 in contact with the heated mold has gelled and the resulting form has solidified and possesses structural integrity.
The mold 17 is then closed with the lid 18 and sealed with the toggle bolts 20, 21 and 22, and the contents permitted to rise to fill the mold 17 (Figure 12).
The foaming material in the mold is allowed to cure sufficiently so that it will retain the desired form.
The time required ranges from between about 6 to about 10 minutes and varies with the ingredients of the formulations and the amount and type of catlyst utilized. The resulting composite foam cushion 10 is then removed from the mold 17 and, if desired, crushed through squeeze rollers to mechanically open closed cells and allowed to further cure. When used as a cushion, it is inverted 180 so that the firm supportive layer 11 is at the bottom and the soft layer 12 is at the top as seen in Figures 1 to 4.
In the preferred practice of the invention, the formulations which will eventually form the firmer supportive areas of the cushion are added first. These formulations have the slowest reaction time of the formulations employed which usually is a result of their having less catalyst proportionately than the later used formulations. The foam formulation with the next lowest proportional concentration of catalyst and next slowest reaction time is added next, and so on.
The embodiment of the cushion 110 seen in Figures 5 and 6 differs from that of the embodiment of
Figures 1 to 4 in that the bottom 111 is comprised of two firm foams 111 a and 111 b of different firmness, the soft layer 112 is comprised of two soft foams of different firmness 112a and 112b and the sides 115 and 116 also are each comprised of two foams of different firmness i.e. foams 115a, 115b and 116a and 116b, respectively. If desired, either or all of the bottom, soft layer, caps and sides may be formed of one, two or more foams of different firmness.
The following examples will further illustrate the advantages of the present invention, and provide a more complete understanding of the preferred process.
Examples and Materials
The mold employed was similar in shape to that shown in Figures 7 to 12. It measured approximately 17" x 19" x 5" and was equipped with a lid and toggle bolts to hold the lid in place. The mold 17 was of die cast aluminum and heated to about 100 to about 120'F.
In the Examples the following formulations were used.
Formulation No.1 100 Index Grams
Polyether triol, 4800 M.W. hydroxyl number 34.0 (NIAX Polyol 11-34) 63.20
Acrylonitrile Polymer Polyol hydroxyl number 28.0 (NIAX Polyol 31-28) 35.00
Diethanolamine 1.80
Water 2.30
Tertiary amine catalyst 1.90
Non-hydrolyzable silicone surfactant (L5309) 0.60
Fluorocarbon blowing agent 8.00
Quasi Prepolymer 32% free NCO (NIAX isocyanate SF 50) 41.70
Formulation No. 2 105 Index Grams
Polyether triol, 4800 M.W. hydroxyl number 34.0 (NIAX Polyol 11- 34) 60.19
Acrylonitrile Polymer Polyol hydroxyl number 28.0 (NIAX Polyol 31-28) 33.33
Diethanolamine 1.71
Water 2.19
Tertiary amine catalyst 1.80
Non-hydrolyzable silicone surfactant (L5309) 0.57
Fluorocarbon blowing agent 7.61
Quasi Prepolymer 32% free NCO (NIAX isocyanate SF 50) 41.70
Formulation No. 3 95 Index Grams
Polyether triol, 4800 M.W. hydroxyl number 34.0 (NIAX Polyol 11- 34) 66.52
Acrylonitrile Polymer Polyol hydroxyl number 28.0 (NIAX Polyol 31-28) 36.85
Diethanolamine 1.89
Water 2.42
Tertiary amine catalyst 2.00
Non-hydrolyzable silicone surfactant (L5309) 0.63
Fluorocarbon blowing agent 8.42
Quasi Prepolymer 32% free NCO (NIAX isocyanate SF 50) 4170
Formulation No. 4 90 Index Grams
Polyether triol, 4800 M.W. hydroxyl number 34.0 (NIAX Polyol 11- 34) 70.22
Acrylonitrile Polymer Polyol hydroxyl number 28.0 (NIAX Polyol 31-28) 38.88
Diethanolamine 2.00
Water 2.55
Tertiary amine catalyst 2.11
Non-hydrolyzable silicone surfactant (L5309) 0.66
Fluorocarbon blowing agent 8.88
Quasi Prepolymer 32% free NCO (NIAX isocyanate SF 50) 41.70
Formulation No. 5 80 Index Grams
Polyether triol, 4800 M.W. hydroxyl number 34.0 (NIAX Polyol 11- 34) 79.00
Acrylonitrile Polymer Polyol hydroxyl number 28.0 (NIAX Polyol 31-28) 43.75
Diethanolamine 2.25
Water 2.88
Tertiary amine catalyst 2.38
Non-hydrolyzable silicone surfactant (L5309) 0.75
Fluorocarbon blowing agent 10.00
Quasi Prepolymer 32% free NCO (NIAX isocyanate SF 50) 41.70
Formulation No. 6 80 Index Grams
Polyether triol, 4800 M.W. hydroxyl number 34.0 (NIAX Polyol 11- 34) 75.00
Acrylonitrile Polymer Polyol hydroxyl number 28.0 (NIAX Polyol 31-28) 43.75
Ethoxylated triethanolamine hydroxyl number 635 (Thanol SF 265) 6.25
Water 3.13
Tertiary amine catalyst 1.69
Organo-tin catalyst 0.04
Non-hydrolyzable silicone surfactant (L5309) 1.25
Fluorocarbon blowing agent 10.00
Modified poly isocyanate 40% free NCO (Mondur MT 40) 40.76
Formulation No. 7 85 Index Grams
Polyether triol, 4800 M.W. hydroxyl number 34.0 (NIAX Polyol 11- 34) 70.58
Acrylonitrile Polymer Polyol hydroxyl number 28.0 (NIAX Polyol 31-28) 41.17
Ethoxylated triethanolamine hydroxyl number 635 (Thanol SF 265) 5.88
Water 2.94
Tertiary amine catalyst 1.58
Organo-tin catalyst 0.035
Non-hydrolyzable silicone surfactant (L5309) 1.18
Fluorocarbon blowing agent 9.41
Modified poly isocyanate 40% free NCO (Mondur MT 40) 40.76
Formulation No. 8 100 Index Grams
Polyether triol, 4800 M.W. hydroxyl number 34.0 (NIAX Polyol 11- 34) 60.00
Acrylonitrile Polymer Polyol hydroxyl number 28.0 (NIAX Polyol 31-28) 35.00
Ethoxylated triethanolamine hydroxyl number 635 (Thanol SF 265) 5.00
Water 2.50
Tertiary amine catalyst 1.35
Organo-tin catalyst 0.03
Non-hydrolyzable silicone surfactant (L5309) 1.00
Modified poly isocyanate 40% free NCO (Mondur MT 40) 40.76
Reference Load Indentation Deflections
Formulation No.1 4"x15"x15" Block 1037 gms
25% 67.3
65% 200.5
Sag 2.98
Formulation No. 2 4".#15"x15' Block 1003 gms
25% 73.2
65% 213.7
Sag 2.92
Formulation No. 3 4"x15"x1B Block 1087 gms
25% 59.0
65% 179.0
Sag 3.01
Formulation No. 4 4"x15"x15" Block 1111 gms
25% 49.2
65% 145.2
Sag 2.95
Formulation No. 5 4"x15"x15" Block 1216 gms
25% 35.6
65% 104.6
Sag 2.94
Formulation No. 6 4"x15"x15" Block 1283 gms
25% 1 4.4 65% 44.9
Sag 3.11
Formulation No. 7 4"x15"x15" Block 1223 gms
25% 1 6.3 65% 48.5
Sag 2.98
Formulation No. 8 4"x15"Y15" Block 1026 gms
25% 30.1
65% 87.4
Sag 2.90
The ingredients of Formulations No. 1 to 8 having the brand name NIAX and the silicone surfactant are available from Union Carbide. The ethoxylated triethanol amine (Thanol SF 265) is available from the
Jefferson Chemical Company and the modified polyisocyanate (Mondur) is available from Mobay Chemical. The products of other manufacturers having equivalent properties and serving the same functions can be substituted.
EXAMPLE 1
Formulation No. 3 (205 grams) was poured into Section A and an equal amount was poured into Section B. Then 123 grams of Formulation No. 4 was poured into the front Sections EHE of the mold and 133 grams of Formulation No. 2 were poured into Sections DGD. Next, 123 grams of Formulation No. 4 was poured into the Sections CFC. After a time delay of 30 to 55 seconds during which Formulation No. 4 started to gel, 411 grams of Formulation No. 6 was poured through the rising Formulation No. 2 in Sections DGD. The material was then allowed to fully expand and cure in the mold. The finished cushion after 24 hours of curing had an ILD of 25%, 22.3, 65%, 116.7 and a sag factor of 5.23.
EXAMPLE 2
Formulation No. 4 (210 grams) was poured into Section A and another 210 grams was poured into
Section B. Formulation No. 3 was poured into Sections CFC (120 grams) and Formulation No. 2 was poured into Sections DGD (133 grams). Formulation No. 3 (120 grams) was then poured into Sections
EHE. After a time delay of 35 to 55 second during which Formulation No. 3 started to gel, Formulation
No. 7 (398 grams) was poured into the rising foam in Sections DGD. The material was then allowed to fully expand and cure. After 24 hours the cushion had ILD values of 25%, 28.3, 65% 121.4, and sag factor 4.28.
EXAMPLE 3
The procedure in Example 2 was repeated except that a soft foam Formulation No. 7 (398 grams) was poured into the centres of Section F, G and H through the rising Formulations Nos. 3 and 2. The finished cushion after 24 hours has ILD values of 25% 26.3, 65% 118.4 and a sag factor of 4.50.
EXAMPLE 4
The procedure of Example 2 was repeated except that Formulation No. 2 was poured into both Sections DGD and EHE and that Formulation No. 7 was poured through the rising Formulations Nos. 2 and 3 into the centers of Sections F, G and H. The ILD values of the finished cushion were 25% 25.1, 65% 124.3, and sag factor 4.95.
EXAMPLE 5
Formulation No. 4 was poured into Section A (210 grams) and Section B (210 grams). Formulation No.
3 was poured into Sections CFC (120 grams) and Formulation No. 2 was poured into Sections DGD (133 grams). Formulation No. 1 was then poured into Sections EHE (125 grams). After a time delay of 35 to 55 seconds during which Formulations Nos. 1 and 3 started to gel, Formulation No. 6 (411 grams) was poured into the center of Section D through Formulation No. 2. The lid was then closed and the cushion was allowed to expand. The ILD values after 24 hours of curing were 25% 21.4, 65% 109.5, and sag factor 5.11.
EXAMPLE 6
Formulation No. 3 (210 grams) was poured into Section A and a similar amount was poured into Section B. Next 120 grams of Formulation No. 4 was poured into the front Section CFC and 133 grams of
Formulation No. 2 was poured into middle sections DGD. Formulation No. 1(125 grams) was poured into the back Section EHE. After a time delay of 35 to 55 seconds during which Formulations Nos. 1 2 and 4 started to gel Formulation No 6 (411 grams) was poured through the centers of all the rising foam formulations. The material was allowed to fully expand and cure. After 24 hours Sections EHE had ILD values of 25% 20.1, 65% 85.5 and sag factor 4.25.Section DGD had ILD values of 25% 20.6, 65% 108.4 and sag factor 5.31 and Section CFC had values of 25% 23.2, 65% 112.4 and sag factor 4.84.
EXAMPLE 7
The procedure of Example 6 was followed except that 120 grams of foam Formulation No. 4 was poured in Sections CFC, 133 grams of Formulation No. 1 was poured into Sections DGD and 125 grams of Formulation No. 2 was poured into Sections CFC. The front (Sections EHE) of the finished cushion had
ILD values of 25% 22.1, 65% 77.4, and sag factor 3.50. The middle (Sections DGD) had ILD values of 25% 28.0, 65% 125.0, and a sag factor of 4.47. The rear (Sections EHE) had ILD values of 25% 19.0, 65% 95.7 and sag factor 5.03.
EXAMPLE 8
The procedure of Example 6 was followed except 125 grams of Formulation No. 1 was poured into
Sections EHE, 133 grams of Formulation No. 3 was poured into Sections DGD, and 120 grams of Formulation No. 2 was poured into Sections CFC. The finished cushion had the following ILD values front 25% 20.9,65% 96.9, sag 4.63; middle 25% 23.5,65% 110.7, sag 4.71. Section CFC 25% 22.2,65% 96.6, and sag 4.35.
EXAMPLE 9
The procedure of Example 6 was followed except that 120 grams of Formulation No. 2 was poured into
Sections EHE, 133 grams of Formulation No. 4 was poured into Sections DGD and 120 grams of Formulation No. 1 was poured into Sections CFC.
The finished cushion had the following properties: front 25% 16.9, 65% 101.1, sag 5.98; middle 25% 20.3, 65% 97.5, sag 4.80 and rear 25% 16.9, 65% 83.1, and sag 4.91.
In the cushions formed in Examples 6 through 9, the soft foam layer 12 was completely encapsulated in firmer formulations.
EXAMPLE 10
Formulation No. 3 (210 grams) was poured into Section A and a similar amount was poured into Section B. Formulation No. 4 (120 grams) was poured into Sections EHE and Formulation No. 2 (133 grams) was poured into Sections DGD and Formulation No. 1(125 grams) was poured into Sections CFC. After a time delay of 35 to 55 seconds, two soft foam formulations were poured through the rising foam mass.
Formulation No. 6 (210 grams) was poured into one-half of Section G and the center of Section H and
Formulation No. 7 (200 grams) was poured into the other half of section G and the center of Section F.
The material was then allowed to expand and cure and properties of the cushion were evaluated. The front had ILD values of 25% 13.4, 65% 43.3, and sag factor 3.23. The middle had ILD values of 25% 22.8, 65% 124.2 and sag 5.44. The rear had ILD values of 25% 22.3, 65% 140.3, and sag factor 6.29.
The cushion prepared in this example differed frm all those previously prepared in that it had a soft form layer which was comprised of foams of two different firmnesses. the portion of the soft foam towards the front of the seat was softer than that towards the back of the seat where more support was desired.
EXAMPLE 11 Formulation No. 3 (175 grams) was poured into Section A and a similar amount was poured into Section B. into Sections EHE was poured 120 grams of Formulation No. 4; 133 grams of Formulation No. 2 were poured into Sections DGD and 125 grams of Formulation NO. 1 were poured into Sections EHE.
After a time delay of 35 to 55 seconds, Formulation No. 6 (50 grams) was poured through the rising foam in Section A. In addition, Formulation No. 6 (210 grams) was poured through the rising foam in the center of Sections EHE and one-half of Sections DGD. Formulation No. 7 (200 grams) was then poured through the rising foam in the other half of Sections DGD and the center of Sections CFC. Finally Formulation No. 6 (50 grams) was poured through the rising foam in Section B. The resulting cushion had qeneral overall ILD values of 25% 25.0, 65% 125.0, and sag factor 5.0. The cushion thus obtained had sides or wings (Sections A and B) which were comprised of an exterior softer foam, a supportive firmer middle foam and a still firmer bottom foam. The cushion also had middle and top section which was comprised of foams of two different softnesses.
EXAMPLE 12
Formulation No. 3 (210 grams) was poured into Section A and Formulation No. 5 (235 grams) was poured into Section B. Formulation No. 4 (120 grams) was poured into Sections EHE and Formulation
No. 2 (133 grams) was poured into Sections DGD and 125 grams of Formulation NO. 1 was poured into
Sections CFC. After a time delay of 35 to 55 second Formulation No. 6 was poured through the centers of all the rising foam formulations except in sections A and B. The mold was closed and the material was allowed to expand and cure. After 24 hours the cushion had ILD values of 25% 20.1, 65% 108.4, and sag factor 5.39. The resulting cushion had one side or wing which was of firmer density than the other, a generally soft central section of two different foams and a front and back of different foam densities which were both firmer than the foam of the central cushion (Sections DGD).
The articles prepared in the examples were judged by the appearance of the article and its appropriateness for use as a cushion, the appearance of a cross section of the article indicated that there was a clear stratification of the foams of different firmness and a strong knitting line where the foams were joined.
A method of determining the load indentation deflection values was that described in ASTM D 156463T. The sag factor or l.L.D. (65125) index is the ratio of a 65% load value divided by the 25% value. This ratio indicates to some extent a more or less linear relationship between ratings taken to form a resilience curve. A sag factor of 3 to 4.5 pounds is considered acceptable for a seat cushion for a snowmobile or piece of industrial equipment and a sag factor of about 4.5 to about 6.0 is considered acceptable for a passenger vehicle seat or upholstered furniture.
Although for purposes of illustration specific formulations have been described, it will be readily understood by those skilled in the art that any foam formulations which yield foams having the desired properties when used in the method of the invention can be employed. The selection of ingredients will depend upon the function the foam layer is desired to perform. When the function of the firm foam layer is to provide high support, a high ILD foam is preferred. However, if the primary function of the firm foam layer is to provide an energy absorbing layer, the formulation should be designed to yield a semiflexible foam with a high degree of cross linking. intermediate firmness foams can be used where they provide sufficient support for the intended use. The soft foam layer is preferably a high resiliency low ILD foam.However, any soft foam formulation which results in a soft foam layer which functions as a comfortable load distributor and gives the overall cushion a soft and luxurious feel can be employed.
Polyurethane foams are formed by the reaction of a polyol and a polyisocyanate in the presence of a blowing agent, a catalyst, water and surfactant. The blowing agent, water, and isocyanate reaction produce gases for foaming, the catalyst speeds the reaction and the surfactant stabilizes the rising foam and controls cell size. By varying the type and amount of these ingredients, urethane foams can be made by those skilled in the art to meet the requirements of the firm, supportive layer and soft, comfortable layer.
It will be apparent to those skilled in the art that a number of modifications may be made without departing from the spirit and scope of the invention. It is, therefore, to be understood that the scope of the present invention is not to be limited except by the claims which follow:
Claims (9)
1. A composite foam seat cushion has a bottom of firm supportive foam, a layer of soft foam on top of the bottom, a protective foam cap covering the front edge of the soft top foam, a protective foam cap covering the back edge of said soft layer and supportive foam sides, all of said foams being bonded to adjacent foams without the use of adhesives.
2. The foam seat cushion of claim 1 in which the bottom is comprosed of a plurality of firm supportive foams of different firmness.
3. The foam seat cushion of claim 1 in which the layer of soft foam is comprised of a plurality of soft foams of different firmness.
4. A method of preparing a composite foam seat cushion having a bottom of firm supportive foam, a layer of soft foam on top of the bottom, a protective foam cap covering the front edge of the soft foam layer and supportive foam sides which comprises placing in the center of a suitable mold a relatively slow reacting formulation which will produce a firm supportive foam bottom of a cushion, placing in the front of the mold a formulation which will produce a foam of suitable properties to serve as a protective cap for the front edge of the soft layer, placing in the back of the mold a formulation which will produce a suitable back cap, placing on the sides formulations which will produce sides of desired properties, allowing the formulations to foam and start to rise and the formulations in the front and back to also start to gel and then pouring through the formulations in the mold a faster reacting formulation which will produce the soft layer.
5. The method of claim 4 in which the formulations are polyurethan form formulations.
6. A composite foam seat cushion made by the method of claim 4.
7. A composite foam cushion comprised of foams of different firmnesses, said cushion having a bottom formed of a firm supportive foam, a top or encapsulated layer of soft foam on the bottom, a cap of firm protective foam covering the front edge of said layer of soft foam, a second cap of firm supportive foam covering the back edge of said layer of soft foam and supportive side walls of firm foam, all of said foams being bonded together without the use of adhesives to form an integral cushion.
8. A composite foam cushion substantially as hereinbefore described with reference to and as shown in the accompanying drawings.
9. A method of preparing a composite foam cushion substantially as herein before described with particular reference to examples 1-12.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US62909284A | 1984-07-09 | 1984-07-09 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB8509394D0 GB8509394D0 (en) | 1985-05-15 |
| GB2161375A true GB2161375A (en) | 1986-01-15 |
Family
ID=24521547
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB08509394A Withdrawn GB2161375A (en) | 1984-07-09 | 1985-04-12 | Composite foam-seat cushion and method of preparation |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US4726086A (en) |
| JP (1) | JPS6149813A (en) |
| DE (1) | DE3514058A1 (en) |
| FR (1) | FR2567008A1 (en) |
| GB (1) | GB2161375A (en) |
| IT (1) | IT1182738B (en) |
| SE (1) | SE8502128L (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2183470A (en) * | 1985-11-29 | 1987-06-10 | Aprica Kassai Kk | Child's safety seat |
| GB2197659A (en) * | 1986-11-20 | 1988-05-25 | Bp Chem Int Ltd | Process for preparing polyurethane foams having zones of differing hardness |
| GB2199739A (en) * | 1986-12-01 | 1988-07-20 | Bridgestone Corp | Cushion |
| EP0303883A1 (en) * | 1987-08-14 | 1989-02-22 | Bayer Ag | Process for producing foamed cushions from at least two foamable materials, in particular from reaction mixtures of foamable polyurethanes with correspondingly different elasticity, hardness and flowability characteristics |
| EP0695527A1 (en) * | 1994-08-05 | 1996-02-07 | Aprica Kassai Kabushikikaisha | Seat for child-care implement |
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| US5553924A (en) * | 1994-11-15 | 1996-09-10 | The Board Of Trustees Of The University Of Alabama For Its Division, The University Of Alabama At Birmingham | Vehicle safety seat system |
| US5498381A (en) * | 1994-12-21 | 1996-03-12 | Milsco Manufacturing Company | Method of forming and piercing a thermoplastic strip in one step |
| US5569420A (en) * | 1995-02-06 | 1996-10-29 | Van Horne; Bret L. | Method of forming a foam core comprising a plurality of arcuate rows |
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| WO1998008426A1 (en) * | 1996-08-30 | 1998-03-05 | Arnold Balonick | Multiple component mattress with silicone fiber filled layer |
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| US6447058B1 (en) * | 1999-06-25 | 2002-09-10 | Nubax Vertical Innovations, Llc | Seat means for preventing shock |
| DE19957397C1 (en) * | 1999-11-29 | 2001-07-19 | Technogel Gmbh & Co Kg | Moldings made of polyurethane and process for its production |
| JP3779172B2 (en) * | 2001-04-16 | 2006-05-24 | テイ・エス テック株式会社 | Manufacturing method for vehicle seat |
| AU2002349469A1 (en) * | 2001-11-26 | 2003-06-10 | Bridgestone Corporation | Seat pad for vehicle |
| US20040164113A1 (en) * | 2002-12-12 | 2004-08-26 | Milsco Manufacturing Company, A Unit Of Jason Incorporated | Insulated carrier for wheeled vehicle |
| EP1591221B1 (en) * | 2002-12-24 | 2015-10-28 | Bridgestone Corporation | Method of producing a polyurethane foam product |
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| US10286824B2 (en) | 2016-08-24 | 2019-05-14 | Ford Global Technologies, Llc | Spreader plate load distribution |
| US10279714B2 (en) | 2016-08-26 | 2019-05-07 | Ford Global Technologies, Llc | Seating assembly with climate control features |
| US10391910B2 (en) | 2016-09-02 | 2019-08-27 | Ford Global Technologies, Llc | Modular assembly cross-tube attachment tab designs and functions |
| US10239431B2 (en) | 2016-09-02 | 2019-03-26 | Ford Global Technologies, Llc | Cross-tube attachment hook features for modular assembly and support |
| US9914378B1 (en) | 2016-12-16 | 2018-03-13 | Ford Global Technologies, Llc | Decorative and functional upper seatback closeout assembly |
| US10889489B2 (en) * | 2017-02-15 | 2021-01-12 | Joseph T. Nilson | Composite cushions |
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| US10703239B2 (en) * | 2017-11-13 | 2020-07-07 | Gulfstream Aerospace Corporation | Seat assembly including a modular foam arrangement and method for fabricating the same |
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1985
- 1985-04-12 GB GB08509394A patent/GB2161375A/en not_active Withdrawn
- 1985-04-18 DE DE19853514058 patent/DE3514058A1/en not_active Withdrawn
- 1985-04-30 FR FR8506588A patent/FR2567008A1/en not_active Withdrawn
- 1985-05-02 SE SE8502128A patent/SE8502128L/en not_active Application Discontinuation
- 1985-06-05 IT IT48169/85A patent/IT1182738B/en active
- 1985-06-07 JP JP60122845A patent/JPS6149813A/en active Pending
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1986
- 1986-08-11 US US06/895,358 patent/US4726086A/en not_active Expired - Fee Related
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| GB1241829A (en) * | 1967-08-02 | 1971-08-04 | Himolla Hierl Gmbh C | Seats |
| GB2063065A (en) * | 1979-11-13 | 1981-06-03 | Tachikawa Spring Co | Seat cushion |
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Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2183470A (en) * | 1985-11-29 | 1987-06-10 | Aprica Kassai Kk | Child's safety seat |
| GB2197659A (en) * | 1986-11-20 | 1988-05-25 | Bp Chem Int Ltd | Process for preparing polyurethane foams having zones of differing hardness |
| GB2197659B (en) * | 1986-11-20 | 1990-01-10 | Bp Chem Int Ltd | Process for preparing polyurethane foams having zones of differing hardness |
| GB2199739A (en) * | 1986-12-01 | 1988-07-20 | Bridgestone Corp | Cushion |
| GB2199739B (en) * | 1986-12-01 | 1990-01-24 | Bridgestone Corp | Cushioning stuff and manufacturing method of the same |
| EP0303883A1 (en) * | 1987-08-14 | 1989-02-22 | Bayer Ag | Process for producing foamed cushions from at least two foamable materials, in particular from reaction mixtures of foamable polyurethanes with correspondingly different elasticity, hardness and flowability characteristics |
| US5019304A (en) * | 1987-08-14 | 1991-05-28 | Bayer Aktiengesellschaft | Process for the production of foam cushions from different fluid reaction mixtures |
| EP0695527A1 (en) * | 1994-08-05 | 1996-02-07 | Aprica Kassai Kabushikikaisha | Seat for child-care implement |
| US5615927A (en) * | 1994-08-05 | 1997-04-01 | Aprica Kassai Kabushikikaisha | Seat for child-care implement |
Also Published As
| Publication number | Publication date |
|---|---|
| SE8502128D0 (en) | 1985-05-02 |
| US4726086A (en) | 1988-02-23 |
| IT8548169A0 (en) | 1985-06-05 |
| JPS6149813A (en) | 1986-03-11 |
| DE3514058A1 (en) | 1986-02-06 |
| SE8502128L (en) | 1986-01-10 |
| GB8509394D0 (en) | 1985-05-15 |
| IT1182738B (en) | 1987-10-05 |
| FR2567008A1 (en) | 1986-01-10 |
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| Date | Code | Title | Description |
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| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |